7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Presenter: Prof. Gregory Wagner Project PIs: Gregory Wagnera, Jian Caoa, Brad Kinseyb aNorthwestern University bUniversity of New Hampshire, Durham gregory.wagner@northwestern.edu

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Industrial Needs and Relevance: Advanced processes that reduce production cost and increase yield rate. Effective ways to form/bond difficult-to-form materials or parts with difficult-to-form geometries. Processes that do not deteriorate the quality of formed parts, e.g., their mechanical properties, microstructures and surface finish. NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Project Objectives: Increase production rate and reduce cost by integrating multiple-step processes into a single-step process Increase the process window in metal forming and bonding, especially for difficult-to-form materials Alter microstructure and improve material properties through forming NSF I/UCRC Planning Meeting

Electrically-Assisted Material Deformation CCD camera for DIC strain measurement Micro tensile machine IR camera for recording temperature Material: Nano-particle reinforced Ferritic Alloy Zilin Jiang, Man-Kwan Ng, Qiang Zeng, Kornel Ehmann, Osman Anderoglu, Stuart Maloy, Jian Cao “Electrically-Assisted Forming of Oxide Dispersion Strengthened Structural Materials”, MTS 2017 Valoppi, …., Cao, CIRP Annual 2016

Electrically-Assisted Mixed Double-Sided Incremental Forming (E-MDSIF) Material: Ti6Al4V Valoppi, B., Egea, A.J.S., Zhang, Z.X., Rojas, H.A.G., Ghiotti, A., Bruschi, S. and Cao, J. (2016) “A Hybrid Mixed Double-Sided Incremental Forming Method for Forming Ti6Al4V Alloy”, Annals of CIRP, Vol. 66 (1) Valoppi, …., Cao, CIRP Annual 2016

Electrically-Assisted Bonding Images of interface cross-sections in (a) Al/Al at 60% thickness reduction, and (b) Al/Cu at 40% reduction sheets bonded by roll bonding with or without current. Materials: 127 μm AA1100 Al alloy 127 μm 110 Cu alloy 127 μm stainless steel Ng, M.K., Li, L.Y., Fan, Z.Y., Gao, R.X., Smith, E.S. III, Ehmann, K.F. and Cao, J. (2015) “Joining sheet metals by electrically-assisted roll bonding”, Annals of CIRP, Vol. 65(1), pp. 273-276 Valoppi, …., Cao, CIRP Annual 2016

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Approach/Methodologies: Electrically-Assisted Forming for Enhancing Formability and Joinability Microrolling system Electrically-assisted Roll bonding Multi-physics modeling for the effect of continuous and pulsed current on forming and bonding Microstructure and surface finish characterization of processed parts Analytical modeling of bonding interface in EARB NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Deliverables: Multi-physics, multi-scale modeling of material behavior subject to electrically-assisted forming under continuous and pulsed current Process design guideline for electrically-assisted forming (EAF) Process design guideline for electrically-assisted roll bonding (EARB)

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Improved frictional conditions, and thus less surface galling, achieved. Reduced forces required for micro-extrusion process. Experimental set-up Experimental set-up Tooling Surface condition results Force results Witthauer, A., Kim, G.Y., Faidley, L., Zou, Q., and Slaughter, J. (2010) “Effect of Ultrasonic Vibration on Micro-Extrusion Process”, International Conference on Micro Manufacturing (ICOMM), Madison, WI, April 5-8. Bunget, C. and Ngaile, G. (2011) “Influence of Ultrasonic Vibration on Micro-Extrusion”, Ultrasonics, 51(5), 606-616. NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Approach/Methodologies: Ultrasonic-Assisted Forming for Process Enhancement Candidate processes that will yield economic benefits (micro/meso/macro scale proc., forming load patterns). Availability of high power ultrasonic generators for industrial usage. Tooling design requires reliable numerical modeling: Modal analysis and frequency response analysis (damping ratios which are function of mating surfaces are difficult to determine). NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Approach/Methodologies: Ultrasonic-Assisted Forming for Process Enhancement Ultrasonic metal forming setup Fundamental understanding of ultrasonic forming process: Effects of vibration frequency, mode, and amplitude on flow stress, microstructure and friction. Tooling and system design guideline to acquire resonance frequencies. Strategies to minimize ultrasonic energy input to assess process viability. NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Deliverables: Effects of vibration mode on friction under ultrasonic vibrations. FEA simulations for tool and system design used in ultrasonic-assisted forming. Characterizations of process and material formed by ultrasonic–assisted forming. Variant mode shapes NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Budget and Timeline: - Estimated cost of project is $450K for three years. Task / Milestone Year 1 Year 2 Year 3 Q1 Q2 Q3 Q4 Material characterization   Multi-physics modeling Microstructure Characterization Design guideline NSF I/UCRC Planning Meeting

7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming Discussion: Are the industrial need and relevance accurately captured? Are the objectives realistic and complete? Are the approaches technically sound and appropriate? Are there alternative implementation paths or better approaches? Are the deliverables impactful to industrial partners? Are the budget and timeline reasonable? Are there conflicts with intellectual property or trade secrets? List additional project specific questions are appropriate. NSF I/UCRC Planning Meeting